AMERICAN NATIONAL STANDARD

ANSI/ISA91.00.012001
Reaffirmation and Redesignation of ANSI/ISA91.011995

Identification of Emergency Shutdown Systems and Controls That Are Critical to Maintaining Safety in Process Industries

NOTICE OF COPYRIGHT
This is a copyrighted document and may not be copied or distributed in any form or manner without the permission of ISA. This copy of the document was made for the sole use of the person to whom ISA provided it and is subject to the restrictions stated in ISAs license to that person. It may not be provided to any other person in print, electronic, or any other form. Violations of ISAs copyright will be prosecuted to the fullest extent of the law and may result in substantial civil and criminal penalties.

Reaffirmed 28 March 2001

TM

ISAThe Instrumentation, Systems, and Automation Society

ANSI/ISA91.00.012001 Identification of Emergency Shutdown Systems and Controls That Are Critical to Maintaining Safety in Process Industries ISBN: 1-55617-756-9 Copyright 2001 by ISAThe Instrumentation, Systems, and Automation Society. All rights reserved. Not for resale. Printed in the United States of America. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), without the prior written permission of the Publisher. ISA 67 Alexander Drive P. O. Box 12277 Research Triangle Park, North Carolina 27709 USA

ANSI/ISA91.00.012001

Preface
This preface, as well as all footnotes and annexes, is included for information purposes and is not part of ANSI/ISA91.00.012001. This document has been prepared as part of the service of ISAThe Instrumentation, Systems, and Automation Society, toward a goal of uniformity in the field of instrumentation. To be of real value, this document should not be static but should be subject to periodic review. Toward this end, the Society welcomes all comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices Board; ISA; 67 Alexander Drive; P. O. Box 12277; Research Triangle Park, NC 27709; Telephone (919) 549-8411; Fax (919) 549-8288; E-mail: standards@isa.org. The ISA Standards and Practices Department is aware of the growing need for attention to the metric system of units in general, and the International System of Units (SI) in particular, in the preparation of instrumentation standards. The Department is further aware of the benefits to USA users of ISA standards of incorporating suitable references to the SI (and the metric system) in their business and professional dealings with other countries. Toward this end, this Department will endeavor to introduce SI-acceptable metric units in all new and revised standards, recommended practices, and technical reports to the greatest extent possible. Standard for Use of the International System of Units (SI): The Modern Metric System, published by the American Society for Testing & Materials as IEEE/ASTM SI 10-97, and future revisions, will be the reference guide for definitions, symbols, abbreviations, and conversion factors. It is the policy of ISA to encourage and welcome the participation of all concerned individuals and interests in the development of ISA standards, recommended practices, and technical reports. Participation in the ISA standards-making process by an individual in no way constitutes endorsement by the employer of that individual, of ISA, or of any of the standards, recommended practices, and technical reports that ISA develops. CAUTION ISA ADHERES TO THE POLICY OF THE AMERICAN NATIONAL STANDARDS INSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF AN EXISTING PATENT THAT IS REQUIRED FOR USE OF THE STANDARD, IT WILL REQUIRE THE OWNER OF THE PATENT TO EITHER GRANT A ROYALTY-FREE LICENSE FOR USE OF THE PATENT BY USERS COMPLYING WITH THE STANDARD OR A LICENSE ON REASONABLE TERMS AND CONDITIONS THAT ARE FREE FROM UNFAIR DISCRIMINATION. EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THIS STANDARD, THE USER IS CAUTIONED THAT IMPLEMENTATION OF THE STANDARD MAY REQUIRE USE OF TECHNIQUES, PROCESSES, OR MATERIALS COVERED BY PATENT RIGHTS. ISA TAKES NO POSITION ON THE EXISTENCE OR VALIDITY OF ANY PATENT RIGHTS THAT MAY BE INVOLVED IN IMPLEMENTING THE STANDARD. ISA IS NOT RESPONSIBLE FOR IDENTIFYING ALL PATENTS THAT MAY REQUIRE A LICENSE BEFORE IMPLEMENTATION OF THE STANDARD OR FOR INVESTIGATING THE VALIDITY OR SCOPE OF ANY PATENTS BROUGHT TO ITS ATTENTION. THE USER SHOULD CAREFULLY INVESTIGATE RELEVANT PATENTS BEFORE USING THE STANDARD FOR THE USERS INTENDED APPLICATION. HOWEVER, ISA ASKS THAT ANYONE REVIEWING THIS STANDARD WHO IS AWARE OF ANY PATENTS THAT MAY IMPACT IMPLEMENTATION OF THE STANDARD NOTIFY THE ISA STANDARDS AND PRACTICES DEPARTMENT OF THE PATENT AND ITS OWNER. ADDITIONALLY, THE USE OF THIS STANDARD MAY INVOLVE HAZARDOUS MATERIALS, OPERATIONS OR EQUIPMENT. THE STANDARD CANNOT ANTICIPATE ALL POSSIBLE APPLICATIONS OR ADDRESS ALL POSSIBLE SAFETY ISSUES ASSOCIATED WITH USE IN HAZARDOUS CONDITIONS. THE USER OF THIS STANDARD MUST EXERCISE SOUND

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PROFESSIONAL JUDGMENT CONCERNING ITS USE AND APPLICABILITY UNDER THE USERS PARTICULAR CIRCUMSTANCES. THE USER MUST ALSO CONSIDER THE APPLICABILITY OF ANY GOVERNMENTAL REGULATORY LIMITATIONS AND ESTABLISHED SAFETY AND HEALTH PRACTICES BEFORE IMPLEMENTING THIS STANDARD.

The following people served as members of ISA SP91:

NAME G. Ramachandran, Chairman V. Maggioli, Managing Director R. Adamski A. Barrett L. Baruwa N. Battikha K. Bond R. Boyd L. Brown J. Carew M. Casada W. Cohen A. De Souza R. Ehrlicher A. Engels D. Fritsch W. Goble J. Gray C. Hardin D. Haysley T. Hurst W. Johnson N. Kohatriya D. Leonard E. Lewis G. McFarland N. McLeod W. Mostia I. Nimmo R. Raghavan J. Shaw C. Sossman H. Storey R. Szanyi T. Walczak COMPANY Cytec Industries, Inc. Feltronics Corp. Premier Consulting Services Control Equipment Corp. Bechtel Power Corp. Bergo Tech, Inc. Equilon LLC RVB Management and Engineering Consultants, Inc. Advanced Technology Applications Corp. Consultant JBF Assoc., Inc. Kellog Brown & Root Tandem Technology Group Syngenta Praxair, Inc. Fritsch Consulting Service Exida Com LLC Aspen Technology CDH Consulting, Inc. Albert Garaody & Associates Hurst Technologies Corp. E. I. du Pont H-R International, Inc. D. J. Leonard Consultants Consultant Westinghouse Process Control, Inc. Atofina WLM Engineering Co. Baw Architecture UCDS Raytheon Systems, Inc. Process Control Solutions WG-W Safety Management Solutions Equilon Enterprises LLC Exxon Mobil Research Engineering GE Fanuc Automation

This standard was approved for publication by the ISA Standards and Practices Board on 21 March 2001. NAME M. Zielinski D. Bishop M. Cohen M. Coppler COMPANY Fisher-Rosemount Systems, Inc. Consultant Senior Flexonics, Inc. Ametek, Inc.

ANSI/ISA91.00.012001

B. Dumortier W. Holland E. Icayan A. Iverson R. Jones V. Maggioli T. McAvinew A. McCauley, Jr. G. McFarland D. Rapley R. Reimer J. Rennie H. Sasajima I. Verhappen R. Webb W. Weidman J. Weiss M. Widmeyer R. Wiegle C. Williams G. Wood

Schneider Electric Southern Company Advanced Control & Engineering Solutions Ivy Optiks Dow Chemical Co. Feltronics Corp. Merrick & Co. Chagrin Valley Controls, Inc. Westinghouse Process Control Inc. Rapley Consulting Inc. Rockwell Automation Factory Mutual Research Corp. Yamatake Corp. Syncrude Canada Ltd. Altran Corp. Parsons Energy & Chemicals Group EPRI EG&G Defense Materials CANUS Corp. Eastman Kodak Co. Graeme Wood Consulting

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ANSI/ISA91.00.012001

Contents
1 Purpose ............................................................................................................................................ 9 2 Scope ............................................................................................................................................... 9 3 Definitions......................................................................................................................................... 9 4 Procedure ......................................................................................................................................... 9 5 References ..................................................................................................................................... 10

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ANSI/ISA91.00.012001

Purpose

1.1 Establish a procedure to identify the emergency shutdown systems and safety critical controls that are key to maintaining safety in the process industries as defined in the Mechanical Integrity and Maintenance sections of Process Safety Management (PSM) regulations such as Occupational Safety and Health Administration (OSHA) Federal Regulation 29 CFR 1910.119 (reference 5.1), and Risk Management Program (RMP) regulations such as U.S. Environmental Protection Agency Regulation 40 CFR Part 68 (reference 5.2). 1.2 Mechanical integrity and maintenance are major elements in PSM and RMP programs. In this standard, provisions for mechanical integrity and maintenance apply to the following equipment: a) Emergency shutdown systems b) Safety critical controls (including monitoring devices and sensors, alarms, and interlocks)

Scope

2.1 This standard addresses the instruments that are classified as emergency shutdown systems and safety critical controls and establishes requirements for testing and documenting the test results of these systems. This standard does not address codes, regulations, and other requirements that apply only to the nuclear power industry.

Definitions

3.1 basic process control system: the control equipment installed to perform the normal regulatory functions for the process (e.g., PID control and sequential control). 3.2 emergency shutdown system: instrumentation and controls installed for the purpose of taking the process, or specific equipment in the process, to a safe state. This does not include instrumentation and controls installed for non-emergency shutdowns or routine operations. Emergency shutdown systems may include electrical, electronic, pneumatic, mechanical, and hydraulic systems (including those systems that are programmable). Other common terms used for emergency shutdown systems include safety instrumented systems, safety shutdown systems, protective instrument systems, and safety interlock systems. 3.3 safety critical control: a control whose failure to operate properly will directly result in a catastrophic release of toxic, reactive, flammable, or explosive chemical.

4
4.1

Procedure
Identification

4.1.1 Emergency shutdown systems and safety critical controls should be identified during a process hazard analysis for those events judged likely to occur at an unacceptable frequency. 4.1.2 Emergency shutdown systems and safety critical controls shall be identified and documented in a manner that clearly distinguishes them from other control systems, such as the basic process control system.

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4.2

Maintenance and testing

4.2.1 All emergency shutdown systems and safety critical controls shall be periodically tested and maintained in accordance with user system test procedures taking into account system manufacturer recommendations. 4.2.2 The periodic tests of the emergency shutdown systems and safety critical controls shall contain the following minimum documentation: a) Date of inspection b) Name of person who performed the test c) Serial number or other unique identifier of the equipment d) Results of the test as compared to user-defined acceptance criteria e) A description of the test(s) performed

References

5.1 U.S. Department of Labor, Occupational Safety and Health Administration (OSHA), Federal Regulation 29 CFR 1910.119, Process Safety Management of Highly Hazardous Chemicals, Explosives, and Blasting Agents; Final Rule, February 24, 1992. 5.2 U.S. Environmental Protection Agency (EPA), Federal Regulation 40 CFR Part 68, Risk Management Programs for Chemical Accidental Release Prevention.

Developing and promulgating sound consensus standards, recommended practices, and technical reports is one of ISAs primary goals. To achieve this goal the Standards and Practices Department relies on the technical expertise and efforts of volunteer committee members, chairmen and reviewers. ISA is an American National Standards Institute (ANSI) accredited organization. ISA administers United States Technical Advisory Groups (USTAGs) and provides secretariat support for International Electrotechnical Commission (IEC) and International Organization for Standardization (ISO) committees that develop process measurement and control standards. To obtain additional information on the Societys standards program, please write: ISA Attn: Standards Department 67 Alexander Drive P.O. Box 12277 Research Triangle Park, NC 27709 USA ISBN:1-55617-756-9